Apparatus, method and system for calibrating a liquid dispensing system

ABSTRACT

An apparatus, method and system providing for calibration and/or control of a liquid dispensing system is disclosed. The hand-held calibration auditing tool includes a flow meter ( 36 - 37 ) with inlets adapted for quick connection to one or more liquid inputs and/or liquid outputs of a liquid dispensing system ( 10 ). A sensor ( 94 - 95 ) having a data output of liquid flow information for a liquid input to the dispensing system ( 10 ) is operably connected to a controller ( 12 ) to receive the liquid flow information for the liquid input. The controller ( 12 ) provides a dilution rate and other liquid flow information for a liquid product input to a dispenser. The tool may include any number of flow meters, and may also include a flow meter connected to an outlet of a dispenser ( 22 ) for providing flow information.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. Ser. No. 14/053,803,filed Oct. 15, 2013, which is a continuation application of U.S. Ser.No. 13/194,333, filed Jul. 29, 2011, now U.S. Pat. No. 8,590,362 issuedNov. 26, 2013, which is a non-provisional application of Ser. No.61/369,510, filed Jul. 30, 2010, all of which are hereby incorporated byreference in their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to a method, apparatus and system forcalibrating a liquid dispensing system, and more particularly to amethod, apparatus and system for accurately calibrating, auditing andcontrolling dilution of a liquid product dispensed from a liquiddispensing system during installation and over the operational life ofthe dispensing system.

2. Description of Prior Art

Many cleaning and sanitizing processes, whether laundering, warewashingor the like, have as a significant portion of their operating costs theexpense of the formulated aqueous products they use. Furthermore, theeffectiveness of most, if not all, cleaning and sanitizing processes isinextricably linked to supplying a calibrated or measured amount of aformulated aqueous product to the process. Too little product can impairthe effectiveness of a cleaning and/or sanitizing process. Too muchproduct can result in significant waste and adds unnecessary operatingexpenses to a business. For example, hospitality businesses such ashotels, hospitals, restaurants, and the like use liquid detergents andcleaning solutions for laundry and warewashing. These processes requireproper formulation of the solutions to prevent waste and increase theeffectiveness of the cleaning and sanitizing process. To achieve theseobjectives, many efforts have been made to calibrate, control andmeasure the dilution and delivery of concentrated liquid products duringset-up and over the operational lifecycle of the dispenser. Currentcalibration and auditing techniques for a dispenser require the use ofgraduated liquid collection devices or scales, and multiple iterationsof testing to calculate a dilution ratio to properly calibrate and auditthe dispenser. These processes also often directly expose the individualconducting the calibration or audit to concentrated chemicals

The present invention addresses these problems and provides for anapparatus, method and system for quickly connecting a flow meter in-lineto a liquid input of a dispenser for communicating liquid flow data to acontroller for displaying a dilution ratio for accurately calibratingand auditing a liquid dispensing system.

In addition, the present invention addresses the real-time monitoring ofliquid product dispensing, including the rate, volume, calibration andauditing of the liquid product being dispensed to insure the correctdilution ratio is consistently being achieved.

The present invention also addresses the use of real-time and historicalliquid flow data, whether raw or processed, for assessing current andfuture use of the dispenser, liquid product effectiveness, and businessdecisions relating to a dispensing account.

SUMMARY OF THE INVENTION

In one embodiment, the invention is a hand held tool for calibrating andauditing a liquid dispensing system. The tool includes a flow meterhaving an inlet with a connector adapted for connecting the inlet of theflow meter in-line to one or more liquid inputs to a liquid dispensingsystem and a sensor having a data output of liquid flow information fora liquid input to the dispensing system. In a preferred form, the toolincludes a first flow meter having an inlet with a quick-connectoradapted for connecting the inlet of the first flow meter in-line to afirst liquid input, such as a liquid product, of the liquid dispensingsystem, and a second flow meter having an inlet with a quick-connectoradapted for connecting the inlet of the second flow meter in-line to asecond liquid input, such as a liquid diluent, of the liquid dispensingsystem and a controller operably connected to each flow meter to receiveliquid flow information for a liquid input. The tool also may includedampening means, such as a bladder, a length of flexible wall tubing,and/or a check valve at the outlet of the flow meter.

In another embodiment, the invention is a liquid dispensing system. Thedispensing system includes a dispenser having at least one liquid inputconnected in fluid communication to a liquid product and another liquidinput connected in fluid communication to a liquid diluent. A flow meteris connected in fluid communication to each liquid input of thedispenser. The flow meter has a sensor with a data output of liquid flowinformation for each liquid input to the dispensing system. A controlleris operably connected to the data output of the sensor to receive theliquid flow information for each liquid input and display a dilutionratio for the liquid product. At least one of the flow meters mayinclude pulse dampening means to minimize in-line pressure pulses.

In another embodiment, the invention is a method for calibrating andauditing a liquid dispensing system. The method includes the step oftaking a device in-hand having a flow meter operably connected to acontroller. An inlet of the flow meter is removably connected in-linewith a liquid input to the dispensing system. The dispensing system isoperated and liquid flow information is acquired from the flow meter forthe liquid input. In a preferred form, the device includes a first andsecond flow meter and the step of removably connecting an inlet of thefirst flow meter to a liquid product input and an inlet of the secondflow meter to a liquid diluent input. The system may be calibrated usingmeasured liquid flow information. For example, a dilution ratio iscalculable using liquid flow information from the first and second flowmeters.

Additional embodiments include further variations. One or more flowmeters may be positioned at the output of the dispenser where theproduct and diluent have already been mixed. Product concentrations anddilution ratios can be calculated using modified equations, such as byusing the inputs to calculate the output. Such an option can be optimalfor specific dispenser designs when an internal connection to largediameter tube is complicated while the dispenser output can be easilyaccessible. Furthermore, such a configuration would allow for the one ormore flow meters on the output side of the dispenser to act as a checkor proof that the one or more input flow meters are calibrated. Forexample, the one or more flow meters on the output of the dispensercould determine a concentration independent of the flow meter(s) at theinput, and this could be compared to the determined ratios of the inputflow meters to make sure that the proper ratio and/or concentration isbeing output by the dispenser.

Thus, the use of one or more flow meters at the output of the dispensercould alert when there is something wrong with one of the input flowmeters or with the dispenser itself. If the proper ratio of products isbeing added to the dispenser, but an improper ratio is dispensed, thiscould indicate a problem within the dispenser. However, the output couldalso indicate a problem with one or more of the tubes, flow meters, orother components at the input of the dispenser as well. The additionalflow meter or meters at the output would provide another check on thesystem.

Further embodiments may include additional variations. For example, theinvention includes that any number of inputs may be included with thedispensing system. For example, there may be more than one product beingcombined with a diluent to produce a product having a concentration. Insuch a situation, each of the inputs may include a flow meter forcalibrating the amount of product being added to the dispenser formixing. The dispensing system may also include one or more flow metersat the output of the dispensing system to further calibrate the productbefore or during dispensing, as previously discussed. However, in someinstances, only one or less than all of the inputs and/or outputs may beconnected to a flow meter, in cases where it may be desired to keep aneye on some, but not all, products being added to the dispensing system.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the invention, it is believed that the presentinvention will be better understood from the following description takenin conjunction with the accompanying drawings, and which:

FIG. 1A is a schematic representation of the present invention;

FIG. 1B is a schematic representation of another aspect of the inventionshown in FIG. 1A.

FIG. 2A is a cross-sectional view of the flow meter shown in FIG. 1A;

FIG. 2B is a cross-sectional view of the flow meter shown in FIG. 1B;

FIG. 2C is a cross-section view illustrating another aspect of the flowmeter shown in FIG. 2A;

FIG. 3 is a schematic representation of the present invention and adispensing system;

FIG. 4A is a schematic representation of the present invention shown ina commercial laundry system; and

FIG. 4B is a schematic representation of another aspect of the presentinvention shown in a commercial laundry system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings, wherein like numerals represent like partsthroughout the several views, there is generally disclosed at 11 ahand-held tool for calibrating and auditing a liquid dispensing system10. The tool 11 includes generally a pair of flow meters operablyconnected to a controller 12. The controller 12 could be configured toany number of flow meters. As illustrated in FIGS. 1A-B, tool 11includes generally a pair of flow meter assemblies 36-37. Each flowmeter assembly includes a flow meter 42-43. Flow meters 42-43 arepreferably an oval gear meter. However, it is understood that othersuitable flow meters may also be utilized. Other potentially suitabletypes of flow meters include an orifice-square edge, orifice-conic edge,venturi, pitot tube, electromagnetic, turbine, ultrasonic-transienttime, Doppler, rotometer, vortex, or coriolis flow meter. Of the ovalgear meter type, flow meters 42-43 may be configured to acquire liquidflow information from liquid passing through the cavity 107-108 of thebody 44-45 of each respective flow meter by magnetic pulse count oroptical pulse count. A similar oval gear flow meter using magnetic pulsecount is disclosed in application Ser. No. 11/916,785 entitled “OVALGEAR METER” filed on Jun. 8, 2005 and issued Apr. 28, 2009 as U.S. Pat.No. 7,523,660, which is hereby incorporated by reference in itsentirety. Likewise, a similar oval gear meter using optical pulse countfor capturing or acquiring liquid flow information is disclosed inapplication Ser. No. 12/369,501 entitled “FLOW METER” filed on Feb. 11,2009 and is hereby incorporated by reference in its entirety.

As shown, each flow meter 42-43 includes a body 44-45. Within the body44-45 of each flow meter 42-43 are rotors 46-47 as best illustrated inFIGS. 2A-C. The pair of rotors 46-47 are positioned between the inlet 38and outlet 40. Within the flow meter body 44 and created between eachrotor 46-47 are compartments 84 configured to trap a very precise volumeof fluid between the outer oval shape of rotors 46-47 and the innerchamber wall of the flow meter body 44. The trapping of a precise volumeof liquid in the compartment 84 allows flow meter 42 to operate as apositive displacement flow meter. The flow meter operates by repeatedlyfilling and emptying compartment 84 of a known volume of a liquid. Theflow rate is then calculated based on the number of times thesecompartments 84 are filled and emptied. The design of the oval gear flowmeter 42, as previously described, allows the oval shaped gear-toothedrotors 46-47 to rotate within the flow meter body 44 having a specifiedgeometry. As these rotors 46-47 turn, they sweep out and trap a veryprecise volume of fluid between the outer oval shape of the rotors 46-47and the inner chamber walls with none of the fluid actually passingthrough the gear teeth. An oval gear meter is ideally suited formeasurement of viscous fluids or those with varying viscosities. Whilethe flow meter 42 illustrated in FIGS. 2A-C is preferred to be used withthe present invention, it is understood that other suitable flow metersmay also be utilized, such as those described above and incorporatedherein by reference.

Each flow meter 42-43 also includes a sensor 94-95. Suitable sensors,whether optical or magnetic, are described in U.S. Pat. No. 7,523,660and application Ser. No. 12/369,501 noted above. Sensors 94-95 acquireliquid flow information from the rotors 46-47 shown in FIGS. 2A-C. Eachsensor 94-95 includes a connection 14-15 to the controller 12. Theconnection 14-15 may be a wired or wireless connection. For example,controller 12 may include a transmitter and/or receiver for receivingliquid flow information from flow meters 42-43 and communicating liquidflow information to another device or intermediary data storagelocation. In the case where flow meters 42-43 require a power source,the wired connection 14-15 to controller 12 may be used to support theelectrical needs of any device aboard the flow meter assembly 36-37(such as sensors 94-95). A power source may also be configured into eachflow meter assembly 36-37 for powering any electrical needs of the flowmeter assembly. For example, each flow meter assembly 36-37 may be an“active device” electrically powered by an on-board power source such asa battery. In another embodiment, each flow meter 42-43 may be a passivedevice that is powered from a source external to the flow meter 42-43,or the tool 11, and thereby would not require power from another sourceto operate.

In the configuration shown for tool 11 illustrated in FIGS. 1A-B, liquidflow information is communicated from each flow meter 42-43 tocontroller 12 via wired connectors 14-15. Each flow meter assembly 36-37also includes fittings for quickly connecting them in-line to anexisting conduit or an input line of a dispensing system. One type ofquick-connect fitting is illustrated in FIGS. 1A-B. Other quick-connectfittings are contemplated as circumstances may suggest or are renderedexpedient by incorporation of or use of the present invention incombination with various dispensing systems. Various fittings and otherquick-connectors are available commercially and suitable for use inquickly attaching and removing each flow meter assembly 36-37 from an“in-line” position to an “out-of-line” position relative to a conduit orother liquid carrying member of a dispensing system. For example, asshown in FIGS. 1A-B, the inlet 38-39 and/or the outlet 40-41 of eachflow meter assembly 36-37 may be configured with fittings 86-89. Eachfitting 86-89 has a first end that is inserted into the inlet 38-39 suchas by threading the first end into the inlet. The fittings 86-89 alsoinclude a second end, such as a threaded end, adapted for receiving, bythreads, a quick connector 90-93. A liquid carrying member, such as aconduit, is inserted into the second end of fittings 86-89 and the quickconnector 90-93 is threaded onto the second end. The conduit is sealedto the fitting as the quick connector 90-93 is threaded onto thefitting. For example, a compression seal ring may be used to seal theconduit to the fitting. These types of fittings are commonly known andcommercially available. In this manner, the inlets 38-39 and/or outlets40-41 may be quickly connected in-line with an existing liquid carryingmember such as a conduit, hose, tubing or pipe of a dispensing system.Those skilled in the art can appreciate that the quick connectors orfittings being contemplated are not limited to threaded unions but mayinclude other attachment interfaces, such as a quick coupler union, acompression fit union, a slip joint union, a gasket fit union, or anyother connection union having the structure to permanently ortemporarily hold cooperating attachment interfaces together, such as theinlets 38-39 and/or outlets 40-41 of each flow meter assembly 36-37 witha liquid carrying member, such as conduit, hose or pipe.

FIGS. 1B and 2B-C illustrate other possible aspects of the presentinvention that may be included with a flow meter assembly. In oneaspect, one or both flow meter assemblies 36-37 may include a length offlexible tubing 110 connected at the outlet. The tubing 110 ispreferably constructed of thin, flexible walls so as to allow in-linepressure changes, specifically back pulses, to be absorbed by the tubingto prevent or minimize the in-line pressure changes from reverserotating the rotors 46-47 and 82-83. For example, in-line pressurechanges can result from a pressure or pump source that is used to moveliquid through a dispensing system. In one embodiment, the tubing 110 ispreferably a low (e.g., 44-55 durometer hardness) durometer tubing ofsufficient length (e.g., roughly six inches) to absorb in-line backpulses by providing minimal resistance to tube compression. The tubing110 may be connected at the outlet 38-39 of the flow meter assembly. Theopposite end of the tubing 110 may be connected in-line with an existingliquid carrying member such as a conduit, hose, tubing or pipe of adispensing system using the fittings 86-89 and connectors 90-93.Alternatively, the opposite end of the tubing 110 may be connected to acheck valve 112. The check valve 112 is configured to prevent liquidfrom flowing backwards through the flow meter assemblies 36-37 as aresult of inconsistent line pressure, such as from a back pulse. Sincethe check valve 112 is not always quick enough to entirely prevent aback pulse from reaching the meter, the tubing 110 further dampens whatthe check valve 112 misses. In this manner, the tubing 110 and checkvalve 112 work together to prevent in-line pressure inconsistencies,such as a back pulse, from reaching the meter and reverse-rotating therotors. As best illustrated in FIG. 2B, one end of the check valve 112may be configured with fittings 86-89 and connectors 90-93 to beconnected in-line with an existing liquid carrying member such as aconduit, hose, tubing or pipe of a dispensing system. In another aspectof the present invention as shown in FIG. 2C, the flow meter assembly36-37 may include a bladder 114 or a belt at the outlet of the cavity107-108 to absorb inconsistent line pressures, such as a back pressurepulse. The bladder 114 or belt may be constructed of ultra-soft tubing(e.g., ultra-low or low durometer tubing) or a thinned membrane so thatit provides minimal resistance to compression, and thereby absorbspressure that might otherwise reverse-rotate the rotors 46-47.

Controller 12 is operably configured to provide data storage,communication and processing. Data in the form of liquid flowinformation is received from each flow meter assembly 36-37. The liquidflow information is preferably reported to the controller 12 from eachflow meter assembly 36-37 in units such as a volume per unit of time(i.e., volumetric flow). Given that each dispensing system has bothliquid inputs and liquid outputs with varying liquid flow rates, eachflow meter assembly 36-37 may be specifically configured for a measuringa certain volumetric flow rate. This includes measuring flow rate, totalconsumption, and other parameters associated with any liquid orliquidized flow. Any of the aforementioned measurements may also beelectronically date time stamped for purposes of analyzing measurements.For example, a high volume flow meter may be used to connect in-line tothe liquid diluent line of a dispenser whereas a lower volume flow metermay be used to connect in-line to the liquid product line of adispensing system.

The controller 12 is also preferably configured to identify the type offlow meter (e.g., flow rate for the meter) connected to the controller12. In one embodiment, connectors 14-15 are configured with a pin-outhaving a specific number of pin connectors depending upon the type offlow meter being connected to the controller 12. Alternatively,connectors 14-15 may have a different configuration for the pin-out. Forexample, a connector with four pins could only have two wires. Wiresgoing to pins 1 and 2 would be a different flow meter than the one withwires going to pins 2 and 3, or 3 and 4, etc. Altering the configurationof the wired pins enables one common connector to be used todifferentiate between multiple size gear meters. Thus, depending uponthe number of pins in the pin-out, the controller automaticallyrecognizes the type of meter and its flow rate and sensitivityparameters. Auto recognition of the type of flow meter, flow rate andsensitivity parameters for the flow meter may be used to tag liquid flowinformation received from each of the flow meter assemblies 36-37 atcontroller 12.

The controller 12 also includes a display 16 with controls 17. Thedisplay 16, such as an LCD, is configured to apprise the operator of atleast such information as the flow rate for each flow meter assembly36-37 and the dilution ratio for a liquid product flowing through one ofthe meters. Through the display 16, a user may also be apprised of theflow rate for the liquid diluent or product flowing through each meter36-37. Inputs from a user are received through controls 17 forcontrolling information provided on display 16, data processing and datastorage protocol and procedures. Controls 17 may also be provided formanaging transfer of liquid flow information from the controller 12 orpair of flow meter assemblies 36-37 to other electronic devices, such asa PC. The controller 12 is preferably also configured with a processor102 operably connected to a data store 104 and a data link 106. Liquidflow information received from the pair of flow meter assemblies 36-37may be saved in the data store 104 along with date time stampinformation for the recorded data. The liquid flow information may alsobe processed by processor 102 to provide and display information to theoperator via display 16. Liquid flow information in the data store 104or processed by processor 102 may be communicated to another device orlocation for further inspection, study or processing using data link106. Data link 106 may include a transmitter and a receiver fortransmitting data and receiving data from another electronic device ornetwork. Acquired liquid flow information may be communicated inreal-time to permit real-time monitoring of a dispensing system oraccount. For example, liquid flow information acquired by the flowmeters 36-37 for a dispensing system or account may be communicated backto business providing the dispensing equipment and product to theaccount to control, monitor, audit, calibrate, and assess the account inreal-time. Such information may then be used to service, calibrate,repair and/or upgrade the equipment, as well as monitor the use ofproduct. This information may also be shared with the business using thedispensing equipment and product to make decisions regarding the same.Data link 106 may also include a connector such as a USB port forconnecting controller 12 to another electronic device via a USB cable orother data carrier. The controller 12 may include one or moreelectro-chemical cells such as a depletable or rechargeable battery cellfor powering the electronics aboard the controller. The tool 11 may beconfigured so that the flow meter assemblies 36-37 and the controller 12with connectors 14-15 can be operably stored within a carrying case toallow the tool 11 to be totally portable between liquid dispensingaccounts. The present invention contemplates that device 12 can be alsoa PC (for example, a tablet PC, a notebook or even desktop PC) or asmartphone having a device-specific program or application. In such aconfiguration, the sensors 94-95 can be equipped with a microcontrollerto convert sensor data to a digital data to transfer it to a PC, using,for example USB ports, or wireless transmission. The PC can havecorresponding software to transform the data acquired from the sensorsto a flow rate and a dilution ratio data and present them on the PCscreen.

Existing liquid dispensing systems, such as dispensing system 10illustrated in FIGS. 3 and 4A-B, all include one or more liquid inputsto a dispenser. The liquid inputs to the dispenser generally range fromvarying liquid product types that may or may not be diluted by a liquiddiluent input to the dispenser. Existing devices, systems and methodsfor verifying the accuracy of the dispenser, such as the dilution rateof a liquid product, currently require a lot of resources and time forcalibrating and performing continuing audits of the dispensing systemover time. The tool 11 of the present invention is ideally suited forquickly connecting in-line with conduit or tubing, including an existingdevice or feature of a dispenser, for performing a quick calibration andperforming continuing audits of the dispenser over time. The tool 11 isalso ideally suited for semi-permanent or permanent installation into adispensing system. Numerous types of dispensing systems currently existand are contemplated herein. For example, aspirated dispensers provide ameans for dispensing liquid inputs to an end use process such as anappliance. Further details and written description of the variousfeatures, functions and structure of an aspirating dispensing system aredisclosed in application Ser. No. 11/206,618 entitled “METHOD ANDAPPARATUS FOR DISPENSING A USE SOLUTION” filed on Aug. 18, 2005 andincorporated herein by reference in its entirety. Other dispensers arealso contemplated. For example, dispensers configured to dispense basedon weight, flow, unit volume or unit count are contemplated as a type ofdispensing system that tool 11 could be used to provide calibration,monitoring and on-going audits of the dispenser over time. For example,the tool 11 of the present invention could be used to monitor, calibrateand audit a dispensing system that breaks down a solid to a liquidproduct, dilutes a concentrate to a liquid product, dissolves a tabletto a liquid product, or dispenses a liquid product directly from asource. The tool 11 can be a portable device, or may be integrated intoan existing or contemplated dispensing system as described above. FIG. 3illustrates the tool 11 shown in FIG. 1A being integrated into thedispensing system 10. The tool 11 shown in FIG. 1B could also beintegrated into the dispensing system 10 shown in FIG. 3. FIGS. 4A-Billustrate tool 11 shown in FIGS. 1A-B respectively being used as aportable device for calibrating and auditing the dispensing system 10.

The dispensing system 10 illustrated in FIG. 3 includes a dispenser 22.The dispenser 22 includes four solenoid valves 28-31 (solenoid valve 31not shown). The dispenser 22 also includes several liquid inputs. Forexample, the dispenser 22 may include four liquid product inlet ports18-21 (product inlet ports 19 and 21 are not shown). Each product inletport 18-21 of dispenser 22 is connected in fluid communication to aliquid product source such as a liquid product container 48-51 (liquidproduct container 49 and 51 not shown). Each liquid product inlet port18-21 of dispenser 22 is connected in fluid communication to liquidproduct containers 48-51 via a liquid product conduit 32-35 (liquidproduct conduit 33 and 35 not shown). Flow meter assembly 37 isconnected in-line to liquid product conduit 32. Flow meter assembly 37is also connected to controller 12 by connection 15.

Water or other suitable diluents provided by a water or diluent source54, is delivered under a source pressure by a suitable pressure to awater intake conduit 52. The source pressure is typically from 30 psi to50 psi. A suitable water solenoid 56 is placed in the flow path ofconduit 52 and may be utilized to open and close the flow of the waterthrough the conduit. The intake conduit 52 may be connected in fluidcommunication to an inlet 60 of a boost pump 58. The boost pump 58 maybe used to raise the pressure of the water or diluent from the sourcepressure to a suitable elevated pressure. The outlet 62 of the boostpump is connected in fluid communication to the inlet 23 of dispenser 22via conduit 66 with an anti-siphon valve 64 typically positioned in-linein the flow path of conduit 66. Flow meter assembly 36 is alsopositioned in-line in the flow path of conduit 66 as shown. Flow meterassembly 36 is connected to controller 12 via connection 14. Solenoidvalve 56 is activated to allow water or the diluent to flow at thesource pressure to the boost pump where it may then be elevated inpressure and enters the dispenser 22. In the case where dispenser 22 isan aspirating dispenser, the inlet 23 is connected in fluidcommunication to a passageway (not shown) within the dispenser 22.Product inlet ports 18-21 (and two not shown) are moved into fluidcommunication with the passageway (not shown) within the dispenser 22 byactivation of solenoid valves 28-31 (solenoid valve 31 not shown). Thedispenser 22 includes an outlet port 26 connected in fluid communicationto the passageway. The dispenser 22 includes four liquid productconduits 32-35 (liquid product conduits 33 and 35 are not shown)operably connected to each of the product inlet ports 18-21 (and two notshown). Further details and written description describing the variousfeatures, functions and structure of the dispenser, in the case wheredispenser 22 comprises an aspirating dispenser, are further described inapplication Ser. No. 11/206,618 discussed above.

In one leg of the dispenser 22 liquid product 80 from liquid productcontainer 48 may be provided to dispenser 22 via liquid product conduit34 using a peristaltic pump 96. The peristaltic pump 96 (p-pump)includes an inlet 98 connected in fluid communication to the liquidproduct container 48 and an outlet 100 connected in fluid communicationwith a product inlet port 20 of dispenser 22. Optionally, a flow meterassembly identical to flow meter assembly 36 or 37 may be configuredin-line to the flow path of liquid product conduit 34. Recognizing thatp-pumps have a tendency to create a back pulse in the conduit 34 uponinitial compression of the tubing in the pump, the flow meter assembly37-38 shown in FIG. 1B may be connected in-line to conduit 34 to preventthe back pulse from reaching and counter-rotating the rotors in the flowmeter. As discussed above, the tubing 110 and check valve 112 on thedownstream side of the meter mitigate the back pulse by minimizing orpreventing back flow using the check valve 112 and absorbing the backpulse using the tubing 110. The present invention further contemplatesthat a flow meter assembly may be configured in the liquid flow path ofany liquid input to the dispenser 22 and connected to controller 12.Regardless of the type of liquid input or how the liquid product isprocessed or dispensed, flow meter assemblies may be positioned in-linewith the flow path of each liquid input to the dispenser 22. Each flowmeter assembly would be connected to controller 12 by connectors, suchas by wired connectors 14 and 15. Additionally, each flow meter assemblymay be configured with the optimal flow rate sensitivity depending uponthe liquid input being monitored. For example, a flow meter having anappropriate flow rate sensitivity may be placed in-line to conduit 66for measuring the volumetric flow of liquid diluent passing throughconduit 66 into dispenser 22. Similarly, a flow meter assembly having anappropriate flow meter sensitivity may be placed in-line to the liquidproduct conduit 32, or other liquid input to dispenser 22, for measuringthe volumetric flow of liquid product 78 from liquid product container50 into dispenser 22.

During the initial setup and on-going operation of dispensing system 10,liquid flow information communicated from each flow meter assembly 36-37to controller 12 allows the installer or technician to verify that thecorrect amount of liquid product 78 and 80 is being dispensed relativeto the liquid diluent (e.g., the dilution ratio). During a liquidproduct dispensing event, liquid flow information (e.g., the volumetricflow rate) is communicated from each sensor 94-95 of each flow meterassembly 36-37 and any optional flow meter assemblies connected tocontroller 12. During a dispensing event, solenoid valve 56 opens toallow liquid diluent to pass through conduit 66 to dispenser 22. Flowmeter assembly 36 monitors the flow rate of liquid diluent passingthrough conduit 66. The liquid flow information, or volumetric flow ofthe liquid diluent, is communicated from the flow meter assembly 36 tocontroller 12 via connector 14. Communication of liquid flow data may beaccomplished using either wired or wireless connections. Likewise,liquid product 78 is drawn from liquid product container 50 intodispenser, and both are dispensed through outlet conduit 68 to an enduse application such as a warewashing or laundry appliance. Theprocessor aboard the controller 12 uses the liquid flow data from bothflow meter assemblies 36-37 to calculate a dilution ratio for the liquidproduct being dispensed to the end-use application. Additional data,such as flow rate, total consumption, ounce/gallon readings, may also beacquired from the liquid flow information measured by the flow meterassemblies 36-37. Date time stamps may also be applied to data uponacquisition.

The controller 12 may also be connected in operable communication withthe dispenser 22 and/or peristaltic pump 96 for altering the rate atwhich liquid product 78 and 80 are dispensed from dispenser 22. Usingcontroller 12, the amount of liquid product being dispensed may beincreased or decreased to ensure that the use solution or mixed solutiondispensed via outlet conduit 68 to an end use application is beingdispensed at the correct concentration or dilution ratio. Real-timemonitoring of the dilution ratio may be provided on the display 16 ofcontroller 12. Thus, the controller 12 may monitor, process and storeliquid flow information received from each of the flow meter assemblies36-37, and any additional flow meter assemblies connected to a liquidinput leg of the dispenser, for calibrating and providing on-goingaudits of the dispensing system 10. Liquid flow information or dataacquired from each of the flow meter assemblies 36-37 (and others notshown), whether processed or raw, may be stored aboard the controller 12in a data store 104 for subsequent download to a PC or other electronicdevice. Liquid flow information may also be date time stamped viewed inreal-time or stored for subsequent analysis. Furthermore, controller mayinclude a link for uploading liquid flow information to a network orother system for real-time or post monitoring of the behavior of thedispensing system 10 by a company or technician. The controller 12 isalso able to alert or provide notifications via display 16, or a networkor other connection to allow an operator, user or technician to beapprised of the operating status of the dispensing system 10. Forexample, if the dilution ratio of a liquid product falls outside of thetolerable dilution ratio for that specific liquid product, thecontroller 12 may be configured to apprise the operator, user ortechnician of the malfunction and the subsequent need for service. Thishistorical information or liquid flow data may be saved in a data store104 aboard the controller 12 for subsequent evaluation or use in makingbusiness decisions relating to the dispensing system 10 or thedispensing account. Using the controls 17 of controller 12, a user,operator or technician may gain access to liquid flow data acquired byeach of the flow meter assemblies 36-37 (and those not shown). Throughthe controls 17 aboard controller 12, a user, operator or technician mayalter the amount of the liquid input relative to the liquid diluent toadjust or alter the dilution ratio. In another aspect of the invention,the controller 12 may be undocked from the dispensing system andconnected via a wire or wireless connection to a PC or other electronicdevice for downloading, saving or uploading liquid flow information fromthe flow meter assemblies 36-37 (and others not shown) for subsequentevaluation, and use in making business decisions relating to thedispenser, dilution ratio of the liquid product or the type of liquidproduct being used. In the case of connection to a pump dosed product(such as a p-pump, diaphragm pump, piston pump, gear pump, etc.), thecontroller may also be configured to auto calibrate on startup and autocontrol while running A technician may use the real-time feedback todial in the correct dilution rate during calibration/audit.Alternatively, by auto-control, or manual control by operator input, thecontroller 12 may use the real time feedback to adjust the dispenser toachieve the desired dilution rate.

FIGS. 4A-B are schematic representations of the present invention usedin a commercial laundry system. A laundry system is one type ofcommercial application contemplated by the present invention. Othercommercial applications such as a warewashing system or an on-siteformulator are also contemplated. As previously discussed, the tool 11may be used as a portable device for monitoring, calibrating andauditing liquid dispensing systems on an on-going basis. FIGS. 4A-Billustrate the use of tool 11 shown in FIG. 1A-B respectively tomonitor, calibrate and audit dispensing system 10. For example, tool 11may be used during the initial installation of dispensing system 10 tocalibrate each of the liquid inputs to the dispenser 22 to ensure thateach input is being dispensed to the end use application at the correctdilution ratio. Like the dispensing system shown in FIG. 3, thedispensing system shown in FIGS. 4A-B includes a dispenser 22 havingproduct inlet ports 18-21 (product inlet port 21 not shown). The productinlet ports 18-21 are connected to liquid product containers 48-51 vialiquid products conduits 32-35. Each liquid product container 48-51houses a liquid product 78-81. Each liquid product 78-81 constitutes aliquid input to the dispenser 22. A flow meter assembly 36 or 37 may beplaced in-line to the flow path of a liquid product conduit 32-35. Forexample, as shown in FIG. 4B, in the case where product in the liquidproduct conduit 32-35, liquid in the liquid conduit 66 or liquid and/orproduct in the outlet conduit 68 experiences pressure pulses, andspecifically back pulses, the flow meter assembly 37-38 shown in FIG. 1Bor FIG. 1C may be used to mitigate or prevent the back pulse fromreaching and causing the rotors 46-47 and 82-83 to reverse rotate. Asdiscussed above, the tubing 110 and check valve 112 on the downstreamside of the meter mitigate the back pulse by minimizing or preventingback flow using the check valve 112 and absorbing the back pulse usingthe tubing 110. In the case of the meter shown in FIG. 1C, which may beused alone or in combination with a check valve, the bladder 114 absorbsthe back pulse to prevent it from counter rotating the rotors andproviding a false reading. For example, a p-pump 96 has a tendency tocreate back a pressure pulse each time the tube in the pump iscompressed. This back pressure pulse, if allowed to counter rotate therotors of the meter, would result in the flow meter producing aninaccurate reading. In the case where line pressures are generallyconsistent or constant, the flow meter assembly 37-38 shown in FIG. 1Amay be used to acquire liquid flow information.

A suitable controller 70 provides a low voltage connection to thesolenoid valves 28-31 (solenoid valve 31 not shown) and p-pump 96through an electrical connection 74. The controller 70 receives a signalvia connection 72 from the appliance 76, such as a laundry machine. Theoutlet conduit 68 of the dispenser 22 is connected in fluidcommunication to the appliance 76 to dispense a solution to theappliance. The appliance 76 sends a signal to controller 70. Based onthe desired liquid product being requested by the appliance 76, aninstruction is sent from the controller 70 through electrical connection74 to actuate one of the solenoid valves 28-31. The requested liquidproduct 78-81 is drawn from a liquid product container 48-51 and througha liquid product conduit 32-35 into dispenser 22. The present inventionalso contemplates that the controller 70 could be configured to pulse asolenoid valve 32-35 connected to dispenser 22 to control the dilutionrate. Varying the pulse rate can vary the end use dilutionconcentration. The liquid product and liquid diluent received from theliquid diluent source 54 is dispensed through an outlet port of thedispenser 22 into the appliance 76 via outlet conduit 68. Althoughdispensing system 10 illustrated in FIGS. 4A-B illustrates the featuresof a particular dispensing system, such as an aspirated dispensingsystem, the tool 11 of the present invention contemplates use with anytype of dispensing system. For example, the tool 11 could be used tomonitor, calibrate and audit, on an on-going basis, any type ofdispensing system where liquid inputs to the dispensing system aredispensed to an end use application and there exists a desire to controla dilution ratio or concentration for a liquid input being dispensed tothe end use application. The tool 11 could also be used to monitor,calibrate and audit, on an on-going basis and in real-time, anydispensing parameter extractable from the liquid flow informationacquired by the flow meters 37-38 connected in-line to a liquid carryingmember of the dispensing system. As discussed above, the liquid flowinformation could include the flow rate, total amount dispensed, totalamount consumed, date and time of the readings, etc. The liquid flowinformation could be used by controller 12 to control and provide inputto controller 70 operating the dispensing system 10. For example, tool11 could be used to audit each dispensing event. The liquid flowinformation could be used by controller 70 to verify that the dispensingsystem 10 is operating properly, and if not, the liquid flow informationcould be used for making real-time corrections to each dispensing eventuntil the event matches the system's desired operating parameters.Additionally, the liquid flow information could be recorded and used byan on or off-site user, operator or technician to monitor and makeadjustments to the controller 70 and/or dispensing system 10 as needed.

Whether during the initial setup of the dispensing system or checkingoperation of the dispensing system on an on-going basis or over time,the tool 11 may be used to monitor, calibrate and audit the dispensingsystem to ensure that the liquid and concentration of solutions beingdispensed to the end use application, such as a warewashing or laundryappliance, are correct. As each flow meter assembly 36-37 includes aquick connector 90-93 (shown in FIGS. 1A-B) each flow meter assembly36-37 may be connected in-line of the flow path to any liquid input tothe dispensing system 10. For example, flow meter assembly 36 may beconnected in-line to the flow path of conduit 66 and flow meter assembly37 connected in-line to the liquid flow path of liquid product conduit,such as conduit 34. During a dispensing cycle of liquid product 80 fromliquid product container 48 through liquid product conduit 34, flowmeter assembly 37 acquires liquid flow data which is in-turncommunicated to controller 12. Similarly, during the same dispensingcycle, liquid flow data is communicated from flow meter assembly 36 tocontroller 12 for the liquid diluent passing through conduit 66 into theinlet 23 of dispenser 22. Controller 12 compares the liquid flowinformation received from the flow meter assemblies 36-37 to derive adilution ratio between the liquid diluent being introduced into thedispenser 22 through conduit 66 and the liquid product 80 beingdispensed into the dispenser 22 by peristaltic pump 96. If the dilutionratio of the liquid product being dispensed to the end use applicationis inaccurate or not within the normal bounds for a dilution ratiospecified for the particular product, the dispenser 22 and/orperistaltic pump 96 may be adjusted so that the correct dilution ratiois achieved. Because the flow meter assemblies 36-37 are connectedin-line during the calibration and auditing processes, any changes tothe dispenser 22 or peristaltic pump 96 may be done in real-time, andthe subsequent effect to the dilution ratio may be monitored via thedisplay 16 on controller 12. Each leg of the dispensing system may becalibrated and audited in a similar fashion. This may be done bydisconnecting quick connector fittings 90-93 of one of the flow meterassemblies 36-37 from one liquid input to the dispenser 22 andconnecting to another liquid input line. Before disconnecting, the flowmeter 42 or 43 may be flushed or rinsed to prevent cross-contamination.The controller 70 may be configured with a rinse mode/cycle wherebywater is flushed through the liquid input line to which the flow meterassembly 36-37 is connected. The controller may also be configured tocontrol the volumetric flow of rinse liquid, such as by control of thewater solenoid valve 56, through the flow meter 42-43 so as to not harma flow meter having a low volumetric flow rate. The dispenser 22 isoperated again and the dilution ratio of the liquid product ismonitored, and changes are made in real-time to the dispenser 22 orperistaltic pump 96 for adjusting the dilution ratio. The controller 12may also be used to provide a proof of dose or delivery of a liquidproduct to an end use application. Each flow meter assembly 36-37 may beconnected to a liquid input leg of the dispenser so as to monitor thevolumetric flow of liquid passing through each leg of the dispenser andinto the end use application. Using this procedure, one is able toverify that a specific amount of liquid product has been delivered tothe end use application. In the case where flow meter assembly 36 isconnected in-line to the liquid diluent leg of the dispenser and flowmeter assembly 37 is connected in-line to a liquid product leg of thedispenser, each flow meter assembly may be a specific type with aspecific volumetric flow sensitivity. For example, the flow meterassembly 36 connected in-line to the liquid diluent leg of the dispensermay comprise an oval gear meter wherein the flow information for theliquid input is captured by sensor 94 using a magnetic pulse count.Likewise, the flow meter assembly 37 used to acquire liquid flow datafrom the liquid product line of the dispenser may comprise an oval gearmeter wherein flow information for the liquid product input is capturedby sensor 95 using an optical pulse count. Here, the optical pulse countoval gear meter has a higher sensitivity, can use smaller gears and hasa higher rpm allowability than the magnetic pulse count oval gear meter.Depending upon the desired sensitivity, a flow meter having theappropriate sensitivity may be selected and used with tool 11. Processedor raw flow information data stored or received by controller 12 may beused to monitor and perform ongoing audits of the dispensing system 10.For example, flow information data acquired using each of the flow meterassemblies 36-37 may be used to provide future service or updates to thedispensing system 10. Flow information data may also be used by acompany to make business decisions relating to the liquid products beingused in combination with certain types of dispensers and the appropriatedilution rate for each particular liquid product depending upon its enduse application. The tool 11 allows liquid flow information frommultiple accounts to be acquired and communicated to a remote locationin real-time. The liquid flow information tagged with date time stampinformation may then be used to monitor and perform audits of multipledispensing systems at a single or multiple locations. The liquid flowinformation acquired by the tool 11 may be recorded on a local datastore 104 aboard the controller 12 and/or communicated to one or moreother locations for real-time or post processing, monitoring andauditing.

Additional embodiments of the invention include further variations tothe tool 11 and/or dispensing system 10. For example, there are someoccasions when more than two products, such as the concentrated productand the diluent, will be added to the dispensing system to create adispensed solution, such as a use solution. In such situations, theremay be any number of inputting products that are combined at thedispensing system 10 before being dispensed therefrom. In suchsituations, the tool 11 will include additional flow meters operativelyconnected thereto. For example, if there are to be four products addedto the dispenser 22, the tool 11 can be configured to connect fourseparate flow meters to the conduits directing each of the products tothe dispenser. The flow meters can be placed in line with the conduits,so as to measure the amount of products traveling through each of theconduits and towards the dispenser.

The tool 11 can further be configured to display the data from each ofthe flow meters on the display 16, so that an operator is able to keeptrack, in real time, of the amount of each product and/or diluent thatis being added to the dispenser 22. This would allow the operator toknow the concentration of the combined product at the dispenser, basedupon the amount of products being added.

Thus, the invention contemplates that the tool 11 can be configured tobe used with any number of flow meters at a time, which can match upwith generally any number of inputting products that are being directedtowards the dispenser 22. Furthermore, it may be appreciated that onlysome of the product conduits include flow meters attached thereto, whileothers do not. Such situations may be desired if one or more of theplurality of products is more concentrated, or is otherwise needed to beclosely watched in relation to the remaining products.

Another aspect of the invention provides for two or more products to becombined, with the combination of the products being sent to thedispenser to mix with additional products. For example, a first andsecond product may be combined in a desired ratio. The combined productmay then need to be combined with a diluent at the dispenser 22, beforebeing dispensed. In such a situation, it may be desirable to have firstand second flow meters operatively connected to the conduits of thefirst and second products, in order to know and/or control the amount ofeach passing through to combine with the other, such as in a mixingchamber. However, another flow meter may be positioned in the conduit onthe opposite side of said mixing chamber, in order to control orotherwise calibrate the amount of combined product is to be mixed withthe diluent at the dispenser 22. Therefore, the tool 11 may include afirst flow meter for the first product, second flow meter for the secondproduct, third flow meter at the output of the combined products, and afourth flow meter for the diluent. The combination of the flow meters ofthe tool 11 will provide an operator with the amount of each of theproducts being dispensed.

Therefore, the invention contemplates that the tool 11 can be connectedto and used with any number of flow meters for measuring the amount of aproduct or combined product that is passing through a conduit. The moreflow meters and products used, the greater confidence a user may have inknowing the amount of each product that has been combined to create thedispensed solution.

Furthermore, while the invention has included that the flow meter ormeters be included at the input side of the dispenser 22, it should alsobe appreciated that one or more flow meters could be operativelyconnected to the outlet conduit 68, between the dispenser 22 and theappliance 76 receiving the combined solution. This would provideadditional calibrating for the combined liquids and to measure themixture. The output flow meter or meters could be connected to the sametool 11 as the input flow meters, or could be connected to a separatetool 11. The output flow meter, which could be any of the type of metersheretofore shown and described, could aid in determining theconcentration of the output solution, could aid in controlling theamount of output solution being dispensed to the appliance 76, or couldotherwise be utilized, such as to confirm the concentration or ratio ofinput products.

Product concentrations and dilution ratios can be calculated usingmodified equations, such as by using the inputs to calculate the output.Such an option can be optimal for specific dispenser designs when aninternal connection to large diameter tube is complicated while thedispenser output can be easily accessible. Furthermore, such aconfiguration would allow for the one or more flow meters on the outputside of the dispenser 22 to act as a check or proof that the one or moreinput flow meters are calibrated. For example, the one or more flowmeters on the output of the dispenser 22 could determine a concentrationindependent of the flow meter(s) at the input, and this could becompared to the determined ratios of the input flow meters to make surethat the proper ratio and/or concentration is being output by thedispenser 22.

Thus, the use of one or more flow meters at the output of the dispenser22 could alert when there is something wrong with one of the input flowmeters or with the dispenser itself. If the proper ratio of products arebeing added to the dispenser 22, but an improper ratio is dispensed,this could indicate a problem within the dispenser 22. However, theoutput could also indicate a problem with one or more of the tubes, flowmeters, or other components at the input of the dispenser as well. Theadditional flow meter or meters at the output would provide anothercheck on the system 10.

The above specification, examples and data provide a completedescription of the manufacture and use of the composition of theinvention. Since many embodiments of the invention can be made withoutdeparting from the spirit and scope of the invention, the inventionresides in the claims hereinafter appended.

What is claimed is:
 1. A liquid dispensing system, comprising: adispenser in fluid communication with a plurality of liquid inputs,wherein at least one of the plurality of liquid inputs is in fluidcommunication to a liquid product and at least one of the plurality ofliquid inputs is in fluid communication to a liquid diluent; saiddispenser further comprising a liquid output for dispensing a usesolution to an end-use application; a plurality of input flow metersconnected in fluid communication to each of the plurality of liquidinputs, wherein each of the plurality of input flow meters outputs dataof liquid flow information for each of the plurality of liquid inputs;an output flow meter connected in fluid communication to the liquidoutput of the dispenser, wherein the output flow meter outputs data ofthe liquid flow information for the use solution; a controller operablyconnected to the plurality of input flow meters and the output flowmeter, wherein the controller is configured to receive the liquid flowinformation and to display said liquid flow information; and wherein thecontroller comprises a data store for storing liquid flow informationfor each of the plurality of liquid inputs and the liquid output.
 2. Thedispensing system of claim 1 wherein the controller is a portabledevice.
 3. The dispensing system of claim 1 wherein the controllerfurther comprises a data link configured to connect the controller to aPC to download the flow information.
 4. The dispensing system of claim 1wherein the end-use application comprises at least one of: a. an on-siteformulator, said on-site formulator configured to formulate the usesolution from the plurality of liquid inputs; b. a laundry system; c. awarewashing system.
 5. The dispensing system of claim 1 wherein each ofthe plurality of input flow meters further comprises pulse dampeningmeans.
 6. The dispensing system of claim 1 wherein each of the pluralityof input flow meters includes means for dampening in-line pressurepulses.